Another no start.

[kybishop]

Not having much luck.

I started this in the glow plug/relay sticky but it has now run off the glow plug topic.

1998 Jetta TDI. Two winters ago when I first got it had trouble in the cold temps. New glow plugs, new fuel filter and advanced timing by Paramedic and it ran flawlessly the rest of that winter. Ran flawlessly last winter.

First cold snap this winter and it would not start. Glow plugs were bad, I replaced. Still no start. Checked voltage at glow plug harness and all four checked okay.

I replaced fuel filter and still no start. It would empty the fuel filter each time so I was then going to chase a fuel leak.

55 degrees today, quite the warm spell from -2. Replaced the Thermostatic Valve on top of the fuel filter. No start. I then tried to run it from a jug of diesel to the filter to eliminate any problems with fuel pickup or connections from filter back to tank. Still no start.

I am not sure where to go from here other than a trip to Paramedic. Not wanting to tow though so would rather get it running here at home.

Thanks for any advice on which way to go. I have good voltage at the glow plug harness on all four. May have to chase down fuel connections or vacume connections?

Only thing I changed since the no start the first time; Glow plugs, fuel filter, air filter and thermostatic valve. Any chance that fuel filter could be faulty and pulling in air? I had two filters, one off brand which is the one I put on and is on now. The other is a Bosch that I had planned to use next.

 

[rdkern]

It sounds to me that you had an air leak, and got air into the injector lines. When this happens, it takes FOREVER to purge it unless you crack the lines at the injectors.

First - fully charge your battery. Then while that is happening, make sure you fill your filter (use mity-vac or some such) on the return line. This should get the pump full.

Then, with fully charged battery and cracked injector lines, and cloth around the lines\injectors connections, crank for 20 seconds or so. If fuel has squirted from any of the lines, tighten the wet lines. Wait at least a minute (for the starter's sake) and try again. Be ready to turn it off quickly. Repeat until it starts.

 

[TonyJetta]

Very rarely will fuel filters cause a no-start condition. They will cause an inconsistent run condition.

Are you getting fuel at the injectors? When you loosen the injector fuel lines at the top of the injectors, wrap a dry rag around each injector nut. If the rag is wet after cranking, you have fuel at the injectors and the IP is primed
f not, let us know and we can help you get it primed.

You mentioned that the GP's were changed. Have you verified 12V at each contact on the GP harness?
How to check:
1) Remove the harness from the GP's
2) Disconnect the CTS plug.
3) Turn the key on, while measuring each GP contact.
4) You may need to turn the key off then on a few times to get proper readings.
Interpretation:
1) If you have 12V (battery voltage) at each GP contact, the GP's are working fine.
2) If you have <11V at each GP contact, look at the GP fuse and relay under the dash.
3) If you have 12V at 2 GP contacts and near 0V on the other 2, look at the connection of the GP harness to the round connector at the end of the cylinder head. I'll bet there's one wire hanging loose.

Post back any questions or results.

Tony

 

[kybishop]

I am getting 12V at each contact on the GP harness.

I cracked each injector earlier to see if I was getting fuel. Each one was wet. I cracked them one at a time, cranked on each to see if anything was coming out. Nothing squirting but each was wet. This is how we purged the lines on the Cummins after it sat a while and worked but that is a different animal.

Maybe I do have some air in the lines? The filter seems to keep emptying. I fill it via the opening where the T-valve goes. Then when I check after trying to start there is no fuel visible. It was pulling fuel out of the jug but not enough to keep running.

Maybe hitting on one injector? Seems like the far right (passenger) injector squirted when I cracked it but the others did not. All were wet.

 

[paramedick]

I've seen a few fuel filters that leak fuel from the drain valve. Check to see if any signs of fuel leakage there.

Thermostatic T bad? They do crack and let air into the system.

You said cheap fuel filter. Does it have a proper seal at the opening for the thermostatic T?

I'd pull fuel thru the filter with a mityvac at the outlet to the IP. Then mityvac the return line from the IP to get any air out. Then crack injector lines and crank engine. Fuel will squirt out vigorously. Tighten lines, then try to start.

I've also seen a few IPs putting out such low pressure that they cannot properly pressurize the injectors. Just something to think about. When this occurs, it's usually happens suddenly.

Oh, yeah. Any fuel leaks at the IP? A pump head seal will allow air ingress into the fuel system.

 

[kybishop]

I ended up with two fuel filters somehow. One I bought (Bosch) and this extra one new in package. Not sure of the brand but it has a black O ring for the T-valve. The bosch has the green O-ring. Feels like a tight seal, snapped in.

I will check the filter, IP and lines like you mention. T-valve is new, old had a suspect area. I will mityvac the lines as you describe and check injectors.

Thanks guys.

KB

 

[Mcgink]

Sounds like your drawing air instead of fuel if it will run the filter empty. The O-ring was in the filter itself right? Or is the O-ring on the T itself (A4 style)? The filters/Thermal T's are not interchangable, so make sure that the correct filter is used with whichever style T you have. Correct me if I'm wrong, I believe that The stock set-up would be that the O-ring is in the filter itself (on B4's anyway)

 

[TonyJetta]

Correct me if I'm wrong, I believe that The stock set-up would be that the O-ring is in the filter itself (on B4's anyway)

You are correct A3/B4 era fuel filters have the T-stat O-ring ON the fuel filter.

Tony

 

[kybishop]

Yeah, O-ring on the filter.

Re-did some fuel filter connections and lines. Primed fuel filter. Cracked all four injectors and cranked. Fuel shot out of all four. Closed all four injectors crank, hit a second or two and died. No start.

GP's new and harness tests fine, 60 degrees today anyway. Fuel supply appears fine at least it is squirting out injectors.

Unless what was coming out of the injectors was just what was in the filter. Filter still seems to be running itself out of fuel but I did not check as it got dark. Guess I will need to check the injectors again without refilling the filter?

I don't have a Mityvac. I will check around and see about borrowing one.

Also, the fuel lines from the filter to the IP and visa versa. What do you guys use to replace these? These are black fuel hose with a special factory connection to a clear hose. I had to shorten the one to the IP about half an inch as the end looked questionable.

 

[TonyJetta]

Also, the fuel lines from the filter to the IP and visa versa. What do you guys use to replace these?

Here's what I do to replace the clear fuel lines.

Tony

 

[kybishop]

I am now thinking it is my IP or related to the IP.

I may have been mistaken on it emptying the filter. I may not have filled it up all the way and it was soaking in...doh.

It was full when I went and checked it this last time and it is pulling very little fuel. Some squirts out of the injectors when cracked. It tries to fire but dies immediately. It will hit every time just won't go into a strong idle.

What steps do I need to take in testing my IP? I see no leaks and connections look and feel good. I looked and those things are pretty pricey...but if that is what I need I will certainly get one.

Thanks.

KB

 

[TonyJetta]

That looks like another prothe site. Search tdiclub for 'prothe' you will see the lack of quality and customer service.

One authorized Bosch rebuilder:
Diesel Fuel Injection Service (800-547-8454) of Portland, OR

Tony

 

[sfierz]

Maybe you already posted this but have you checked Injection timing with VCDS? If timing is way off you will get a no-start condition with fuel at the injectors.